CDI TORQUE SURETEST User manual

SURETEST AND 600TL
Model 5000-3
Torque Calibration System
USER’S MANUAL

TABLE OF CONTENTS
Safety Information I
Introduction 1-1
Functional Description and Specifications 2-1
Functional Descriptions 2-1
SURETEST Torque Calibration System 2-1
BaseUnit 2-2
• Front Panel 2-2
• Rear Panel (Input/Output) 2-9
Torque Transducers 2-11
Specifications 2-12
SURETEST Torque Calibration System 2-12
• SURETEST Base Unit 2-12
• Transducers 2-13
• 600TL (LOADER) 2-14
Setup and Programming 3-1
SURETEST Torque Calibration System Setup 3-1
Back panel connections 3-1
Setting Up the SURETEST System 3-2
SURETEST Base Unit Controls 3-3
Powering the Equipment 3-3
Transducer Select 3-4
Programming Setup 3-5
• Setting up Date and Time 3-5
• Setting Up High and Low Limits Alert 3-5
• Programming AUTO Settings 3-6
DATA LIST Memory 3-7
• Clear single memory location 3-8
• Clear all memory location 3-8
Setting Up Printer/PC Ports 3-8
Torque Calibration System Setup 4-1
Testing Torque Wrenches and Drivers 4-1
Selecting a Transducer 4-1
Installing a Transducer 4-1
Dial and Bending Beam Torque Wrenches and Screwdrivers 4-2
Adjustable or Preset “Click” Wrenches and Screwdrivers 4-3
Testing Power Tools 4-4
Non-Impact Tools 4-4
Statistical Analysis 4-7
• Displaying Statistical Analysis on LCD 4-7
• Printing Statistical Analysis 4-8
Displaying or Downloading Data List 4-10
How to Use Analog Output (Rear Panel BNC Connector) 4-11
Calibration 5-1
Mounting Details 5-1
Quick Check 5-4
Torque Transducer Calibration 5-7
TABLE OF CONTENTS 1

SURETEST Base Unit Calibration 5-11
Gravitational Effects 5-14
Correction Factors on Test Weights 5-14
Gravitational Charts 5-15
600TL Manual Loader 6-1
Application 6-1
Torque Tester/Calibrator 6-2
Types of Loader Testing 6-5
• Torque Driver Testing 6-5
Accessories A-1
SURETEST System Components and Inventory Control A-1
Optional Transducers and Accessories A-2
Calibration Accessories A-4
TABLE OF CONTENTS 2

Using this Manual
This manual contains instructions for use and setup of the SURETEST 5000-3 Torque
Calibration System. A table of contents and a table of illustrations are provided to make
this manual easy to use.
Some of the information shown in text or illustrations is obtained using optional
equipment.
Conventions
This section contains a list of conventions used in text.
Chapter References
Additional information in text is referenced by chapter number and section name.
Example:
For testing procedures refer to Chapter 4—Using the SURETEST 5000-3
System.
Equipment Damage
The possibility of damage to vehicle or equipment is introduced by a signal word
indicating this condition.
Example:
IMPORTANT
The connector on single transducer cables contains the EEPROM calibration memory
chip. Never attempt to remove the connector from the transducer. It is installed with a
permanent adhesive.
Safety Messages
Safety messages are provided to help prevent personal injury and equipment
damage. All safety messages are introduced by a signal word indicating the
hazard level. The types of safety messages are: Danger, Warning and Caution.
TABLE OF CONTENTS 3

DANGER Indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury to the operator or to bystanders.
WARNING Indicates a potential hazard which, if not avoided, could result in death or
serious injury to the operator or to bystanders.
CAUTION Indicates a potential hazard which, if not avoided, may result in minor or
moderate injury to the operator or to bystanders.
The three-part message panel, used with safety messages, uses three different type styles
to further define the potential hazard:
• Normal type states the hazard,
• Bold type states how to avoid the hazard, and warning.
• Italic type states the possible consequences of not avoiding the hazard.
Some safety messages contain visual symbols with signal words.
Example:
WARNING
Flying particles can discharge when applying torque.
• Users and bystanders must wear safety goggles.
• Always wear safety goggles when applying torque.
Flying particles can cause injury.
TABLE OF CONTENTS 4

SAFETY INFORMATION
Safety Information
Important Safety Instructions
This manual contains important safety and operating instructions for CDI 5000-3 Torque
Calibration System. Refer to the information in this manual often for safe operation.
Read All Instructions
Read, understand and follow all safety messages and instructions in this manual and on
the test equipment. Safety messages in this section of the manual contain a signal word, a
three-part message.
The signal word indicates the level of hazard in a situation:
• Danger indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury to the operator or bystanders.
• Warning indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury to the operator or bystanders.
• Caution indicates a potentially hazardous situation which, if not avoided, may result in
moderate or minor injury to the operator or bystanders.
The three-part message uses three different type styles to further define the potential
hazard.
• Normal type states the hazard.
• Bold type states how to avoid the hazard.
•Italic type states the possible consequences of not avoiding the hazard.
SAVE THESE INSTRUCTIONS
WARNING
Risk of electric shock and fire.
• For indoor use only. Do not expose charger to rain or snow. Do not use in damp
locations.
• Replace defective cord immediately. Return to qualified service center for replacement.
Electric shock or fire can cause injury.
WARNING
Flying particles can discharge when applying torque.
• Users and bystanders must wear safety goggles.
• Always wear safety goggles when applying torque.
• Do not use this equipment with the power off. Always turn on the indicator and loader
- I -

SAFETY INFORMATION
so the torque and load values are indicated on the display. The safety relays only work
when the power is on. Flying particles can cause injury.
WARNING
Risk of entanglement.
• When starting power tools, check for obstacles near your hand and anticipate the
reaction force by gripping the tool firmly.
• Do not wear loose clothing and jewelry while operating a power tool. Loose clothes
and jewelry can be caught in moving parts.
• Keep body parts away from rotating parts.
• Wear a protective hair covering to contain long hair and prevent contact with moving
parts.
• Do not overreach. Keep proper footing and balance at all times.
Entanglement can cause injury.
WARNING
Improper use can cause breakage.
• Read instructions before operating.
• Follow manufacturer’s instructions, safety precautions, and specifications when
operating tools. Broken equipment can cause injury.
WARNING
• Make sure all components, including adaptors, extensions, drivers and sockets are rated
to match or exceed the torque or load being applied.
• Be sure the capacity of the 5000-3 system matches or exceeds each application before
performing a procedure.
• Do not use the 5000-3 system if it makes unusual noises, has loose parts, or shows any
other sign of damage. Have repairs performed at a CDI Service Center before use.
• Do not use chipped, cracked, or damaged sockets and accessories.
• Do not remove any labels. Replace any damaged label.
• Follow good, professional tool practices:
** Pull on a wrench handle ** do not push ** and adjust stance to prevent a possible
fall.
** Do not use extensions, such as a pipe, on a wrench handle.
• When using ratchets, make sure the direction lever is fully engaged in the correct
position.
• Never attempt to test an impact tool on this instrument.
• Always position the 40" arm over the front of the stand as shown. Never extend the test
arm behind the stand. The stand will tip over when weights are applied.
• Always be alert to the potential for personal injury that may be caused by excessive
torque applications, careless handling of heavy weights, and out-of-balance or unsafe
weight distribution.
- II -

INTRODUCTION CHAPTER 1
CHAPTER 1
Introduction
The SURETEST is a laboratory grade instrument that provides
TORQUE measurements. Although designed as an independent digital
indicator, it can also be used in an integrated environment as the
principal component of a Torque Calibration System. The SURETEST
features versatile data acquisition capabilities including measurement
storage, retrieval, statistical analysis and automatic downloading to an
external printer/computer. A remote computer COM port is available for
PC interfacing.
Used with precision torque transducers, the SURETEST provides high
speed monitoring of static or dynamic torque inputs. Torque transducers,
purchased separately, are available in ranges from 15-200 in.oz, to 200-
2000 ft.lb. and provide system readings with an accuracy of ± 0.25% of
indicated value, or better. A special memory chip is built into each
torque transducer that identifies its range and maintains its calibration
between any other SURETEST with an accuracy of ± 0.5%. The
SURETEST and its transducers may be calibrated by using accessory
precision bars and certified weights.
All readout of torque in ft-lb, in-lb, in-oz, Nm, dNm, cNm, mkg as well
as calibration, statistical analysis and set-up functions are reported on a
versatile 1.5” x 5.5” graphic dot matrix Liquid Crystal Display (LCD).
Set-up and calibration programming is entered using easy-to-use front
panel membrane keys. The number of keys is kept to a minimum. In
addition, concise menus and graphic symbols are used to guide the user
through all set-ups and operations. HIGH and LOW torque limits are
adjustable to give an audible alert. The user selects TRACK mode to
display torque values as they are applied, PEAK HOLD or POWER
TOOL modes to display the highest torque value applied, or FIRST
PEAK mode which captures the torque output at the “click” of a set-able
wrench or driver. CLEAR, STORE and SEND functions can be set up
for automatic or manual operation.
The SURETEST stores and recalls up to 3000 torque readings and does
statistical analysis on them for downloading to printer or computer. The
statistical report (print out) includes a simple histogram for process
monitoring. True RS-232 serial printer and separate RS-232 computer
COM ports are at the back of the unit.
1-1

INTRODUCTION CHAPTER 1
The SURETEST operates directly from any AC power line between 100
VAC to 230 VAC, 50–60 Hz without the need for switch selection. A
hard-wired lithium battery keeps the internal memory and date-time
clock operating for up to 10 years. The real time clock is fully year 2000
compliant.
The information in this manual is general. Operational features,
procedures and specifications may change without notice. CDI Torque
Products makes no claims as to the suitability of this information for
diverse user applications.
1-2

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
CHAPTER 2
Functional Description and Specifications
The CDI 5000-3 is CDI’s next generation Torque Measurement System. It provides
exceptional accuracy and ease of use. It is packaged in a compact, sturdy and attractive
housing unit which requires little room on a laboratory bench. The SURETEST is
typically used in conjunction with a Transducer and a 600TL bench top Mechanical
Loader.
Fig 2-1
Base Unit
The SURETEST monitors and displays the torque applied.
Transducer (Accessory)
The loader accepts all 2000 series single transducers directly. Use a 2000-500-02 adapter
kit to mount the 2000-400-02 4-in-1 transducer. For additional information refer to
Appendix A–Accessories.
Loader Use the 600TL Manual Loader for testing and calibrating all torque wrenches, drivers,
torque multipliers, non-impact pneumatic and electric nut runners. Loader components
are:
• Safety Shield
• Hand Crank
• Transducer Mounting
2-1

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
SURETEST BASE UNIT
Front Panel
Figure 2-2 SURETEST Front Panel
A- Membrane Function ( F1, F2, F3, F4, F5, F6 ), soft keys,
and Cursor/Selection (Up (↑), Down (↓),Left (←), Right (→) and Enter (↵) Keys.
B- Soft Key Menu: Zero, # Data Stored, Setup, Send, Store, Clear, Escape, Format.
C- Real Time Clock. HH:MM:SS
D- Modes: Track, Peak Hold, First Peak and Power tools.
E- Maximum Range of Transducer.
F- Engineering Units : Nm, dNm, Ncm, mkg, cmkg, ft. lb., in. lb., in.oz
G- Power: On/Off
H- Bar Graph: Each dot represents 10% of transducer full scale.
I- Torque Reading: Full 5-digit reading Plus Sign (for direction)
2-2

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
Display
A 240 x 64 Full-featured Graphic LCD is used to provide versatile and clear displays of
system menus as well as measurements. Characters and symbols are displayed in
different fonts:
• Maximum transducer range in the selected UNITS of measure.
• The number of the present data memory location.
Front Panel Membrane Cursor and Function Keys
The SURETEST is supported by a powerful Graphic User Interface (GUI). Set up,
Command, or Control is done by selecting the appropriate Action Item on one of the
provided Menus. Front Panel Membrane Cursor and Functions keys are defined to guide
the User in selecting an Action Item.
There are 6 function (soft) keys: F1 through F6. Their respective uses are clearly
indicated on the LCD.
To select an Action Item, the User simply presses a Function Key (F1-F6) to get to a
Menu, uses a Cursor Key to move to the Item, then hits ‘ENTER’ .
In addition to the ‘ENTER’ key, there are 4 Cursor Keys : Up (↑), Down (↓),, Left
(←), Right (→). The GUI also provides Prompts to further assist the user in navigating
the Menus.
Power Up Sequence
Upon power up, the SURETEST automatically performs Self-tests and displays the
results. Any detected non-functional hardware will be reported on the LCD. If a 4-in-1
transducer is connected, the SURETEST performs ZEROTARE, then displays the
following default menu while continuously checking for any activity from an input
transducer :
The user can either press F1 to display previously collected data (if any) or enter Setup
Mode, F2. Any detected torque measurement will cause the SURETEST to enter
Measurements mode where the following menu is displayed:
2-3

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
The SURETEST returns to the default menu from the measurements mode in the event there is no selection
/ input by the User for more than two minutes. This serves as a reminder for more (input) measurements.
Setup Mode
The following Selections are available:
1. SELECT MODE
2. SELECT UNIT
3. SELECT LANGUAGE
4. MANUFACTURER’S DEFAULTS
5. AUTO SETTINGS
6. EDIT LIMITS
7. CLOCK ADJUST
8. CALIBRATION
9. EDIT PARAMETERS
10. INTERNAL DIAGNOSTIC
11. ABOUT
1. Select Mode
Selects either TRACK, PEAK HOLD, FIRST PEAK, or POWER mode.
• TRACK : continually makes Torque Measurements.
• PEAK : makes Torque Measurement at the Highest Peak.
• 1.PEAK : makes Torque Measurement at the First Peak.
• POWER : makes Torque Measurement at the Highest Peak at a faster rate.
2. Select Unit
Selects the following Torque units on LCD display:
Nm, dNm, cNm, mkg, cmkg, ft. lb., in. lb., in. oz.
2-4

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
3. Select Language
Selects either English, German (Deutsch), French (François), Spanish (Español).
4. Manufacturer’s Defaults:
Default: Min. Track 0.1% ; Min. Peak 1%.
A warning message is first displayed. Upon confirmation by the User, the Default Settings
will be loaded into the SURETEST.
5. Auto Settings
Sets up CLEAR, STORE, and SEND functions. There are 2 options: Automatic or Manual.
Selection: Automatic Clear, Automatic Store and Automatic Send data out (to RS-232 port).
Selection: Delay 9 seconds then clear the Display, Manual Store and Manual Send.
Selection: Automatic Clear, Automatic Store and Manual Send.
2-5

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
6. Edit Limits
Sets up high torque limit preset. (-->) (F4) to go Down 1 line.
Sets up low torque limit preset. (<--) (F5) to go Up 1 line.
Use Up or Down cursor key to increment or decrement the respective value.
Use Left (←) or Right (→) cursor key to select digit.
Press ‘Save’ (F2) to activate the change. Press ‘Clear” (F1) to Clear All Limit set-up.
Press ‘Escape’ (F3) to Exit. Last setup is retained.
7. Clock Adjust
Edits DATE/TIME programming function.
To adjust the Clock, use Left (←) or Right (→) cursor key to get to Day, Month, Year, Hour,
Minute, or Second field. Then use Up (↑), Down (↓), cursor key to increment or decrement the
respective value.
Press and hold the cursor key to change the value quickly.
Press ‘ENTER’ to activate the change.
8. Calibration
This enables the User to perform calibration of the SURETEST base unit and transducers.
(Refer to chapter 5).
2-6

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
9. Edit Parameters
Sets up serial communications protocol.
Sets delay (in ms) per character upon printing.
Sets delay (in ms ) per Linefeed.
Minimum block-out with zero at 0.1% F.S. in Tracking Mode.
Minimum block-out with zero at 1.0% F.S. in Peak-Hold Mode.
10. Internal Diagnostic
For Manufacturer’s use only.
11. About
This provides relevant information regarding the Manufacturer, the software version, and the serial
number of the SURETEST device.
12. Other Features:
Provides manual ZERO TARE.
Stores present measurement to memory (Data 0001 in the example below).
2-7

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
Sets up memory clear options in RECALL mode.
Recalls memory data to display.
Format (F3) calls Statistical analysis to display.
Send (F4). Send data to printer.
Sends all memory data, statistical analysis and histogram to printer port.
Sends data list with or without date-time stamp to computer / printer.
Manually clears display in PEAK, FIRST PEAK, POWER TOOL modes.
2-8

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
SURETEST BASE UNIT
Rear Panel (Input/Output)
Figure 2-3 SURETEST Rear Panel
A - Solenoid Control (Hirose RM15TRD-12S)
(for use with optional 2000-600-02 Loaders)
PIN FUNCTION
10 Loader Relay Common
11 Loader Relay CCW Limit
12 Loader Relay CW Limit
B - Analog Output (BNC)
Analog output provides a voltage level output that is directly proportional to transducer input,
from -1.8V (full scale counter clockwise) to +1.8V (full scale clockwise). Zero offset +/-100 mV.
Linearity +/-1% of reading. Maximum load = 5 mA.
When using the 4-in-1 transducer, zero output fluctuates until one of the transducers is scan
selected by applying 5% of full scale torque.
C - Foot Pedal Switch Input
(used to send output to printer)
D - Fuse Holder
Use AC fuse at specified rating only. ( 3.15 Amp).
E - Input AC Voltage
Automatic Selection of any AC voltage from 100VAC to 230VAC, 50-60 Hz, 50 W.
2-9

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
F- PRINTER PORT (DB-9P)
PIN FUNCTION
2 Receive
3 Transmit
5 Ground
G- OPTIONAL (DB-9P)
PIN FUNCTION
2 Receive
3 Transmit
5 Ground
H- TRANSDUCER INPUT (DB-37S)
PIN FUNCTION
1 not used
2 ground
3 smart chip - bit 2
4 smart chip - bit 0
5 single xducer (-) signal
6 single xducer (+) signal
7 ground
8 4-in-1 xducer (-) signal 2
9 4-in-1 xducer (+) signal 2
10 ground
11 4-in-1 xducer (-) signal 4
12 4-in-1 xducer (+) signal 4
13 4-in-1 xducer LED 2
14 4-in-1 xducer LED 4
15 loader relay CW limit
16 not used
17 not used
18 ground
19 bridge excitation (+3V)
20 not used
21 smart chip - bit 3
22 smart chip - bit 1
23 ground
24 ground
25 4-in-1 xducer (-) signal 1
26 4-in-1 xducer (+) signal 1
27 ground
28 4-in-1 xducer (-) signal 3
29 4-in-1 xducer (+) signal 3
30 no transducer
31 4-in-1 xducer LED 1
32 4-in-1 xducer LED 3
33 loader relay CCW limit
34 loader relay common
35 Vcc (+5V@100 ma. max)
36 ground
37 bridge excitation (+3V)
2-10

FUNCTIONAL DESCRIPTION AND SPECIFICATIONS CHAPTER 2
SURETEST Transducers
SURETEST transducers provide industry standard square drives. They feature a full
bridge strain-gauge @ 350 Ohms nominal. Full range output is 1500 uE, 9mV
(3mV/V @ 3.0V excitation).
Torque transducers use a built-in EEPROM memory chip that stores range identification
and calibration factors. Calibration of transducers is accomplished using precision torque
bars and certified weights. For additional information, refer to Chapter 5—Calibration.
After a transducer is calibrated, it provides ±0.5% system accuracy with any SURETEST
System. If the transducer and SURETEST are calibrated together, the system accuracy
increases to ±0.25%.
Transducer Dimensions/Transducer Torque Range
(Refer to table on page 2-13).
Display Resolution for Transducers
Calibration also results in a specified display resolution on the SURETEST. Display
resolution is dependent on the type of transducer being used. Display resolutions for the
specified transducer are shown on page 2-14.
SURETEST torque transducers can withstand an overload of 110% of full range. The
SURETEST alarms, (audible beep and display “OVER” ) at 110% of rated capacity.
To protect the tool under test or to serve as a fastener installation torque preset alert, the
SURETEST produces a constant audible tone when the input torque exceeds the SET
LOW limit. It then produces a pulsating tone when the input torque exceeds the SET
HIGH limit.
The SURETEST Base Unit ignores inputs less than 0.1% of full range in TRACK mode,
1% in PEAK HOLD mode, 7% in FIRST PEAK and POWER TOOL modes.
With the 4-in-1 transducers, the SURETEST System ignores inputs less than 1% of full
range after scan select.
2-11